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Jeff's MCAD weblogFri, 10 Aug 2018 15:18:42 +0000en-UShourly1https://wordpress.org/?v=4.9.69101563Autodesk’s Forge Transforming the Future of Making Thingshttps://www10.mcadcafe.com/blogs/jeffrowe/2018/08/09/autodesks-forge-transforming-the-future-of-making-things/
https://www10.mcadcafe.com/blogs/jeffrowe/2018/08/09/autodesks-forge-transforming-the-future-of-making-things/#respondFri, 10 Aug 2018 00:00:15 +0000https://www10.mcadcafe.com/blogs/jeffrowe/?p=3162Since its inception in December 2015, Autodesk claims that rapid progress has been made with adopters of its Forge Platform in changing both what and how things are made, and at transforming “the future of making things.”

Simply, the Autodesk Forge Platform is a set of cloud services that connects design, engineering, visualization, collaboration, production, and operations workflows. Application programming interfaces (APIs) and software development kits (SDKs) let software developers of all sizes to build cloud-powered applications, services, and experiences. Admittedly, this is a heady set of claims, but Autodesk is well on its way to fulfilling them.

The cloud-based Forge Platform features APIs and SDKs developers can use to create design, engineering, visualization, collaboration, and other types of enterprise applications. The Forge developer program aims to bring together a community of cloud application developers by providing application development resources.

Forge is an application program interface (API) platform and supporting materials (sample code, manuals) as well as a community of developers who use those APIs. Although Forge is intended for Autodesk customers and 3rd party developers to be able to use its web services. The company uses Forge for its development of cloud-based services, and developers can leverage Forge in the same ways that Autodesk does.

Forge is defined by seven groups of APIs:

Authentication

Authentication for Forge is based on the industry standard OAuth, specifically OAuth2, that provides for token-based authentication and authorization. The basic flow for using OAuth is:

Your app makes an HTTP call to an OAuth REST (REpresentational State Transfer) endpoint and provides its credentials.

A token is returned to your app.

In making subsequent HTTP calls to various APIs on the platform, your app includes the token in a request header.

2. Design Automation API

The Design Automation API provides the ability to run scripts on your design files, taking advantage of the scale of the Forge Platform to automate repetitive tasks. The API currently works with DWG files, but private beta testing is underway for Inventor and Revit files. This is a handy way to publish thousands of drawings to DWF or PDF.

Ordinarily, you would have to download all the files, run a script on them in the AutoCAD desktop software, and then potentially upload them all back to the cloud. Efficiency would be bottlenecked by the processing power of your computer and your network bandwidth, and you would have to instrument logging and retry logic in your code to ensure that the entire job completed. With the Design Automation API, you can offload all that processing to the Forge Platform, which can process those scripts at a much greater scale and efficiency.

3. Reality Capture API

The Reality Capture API lets you use Autodesk’s latest desktop and cloud solution built for Unmanned Aerial Vehicle (UAV) and drone processes, ReCap Photo. You can add geo-based metadata by setting Ground Control Points (GCPs), selecting specific geographic coordinate systems, and tagging images with GPS information. The integration of this geo data results in accurate textured meshes, point clouds, and orthophotos. A reconstruction (Quality) report details the level of accuracy.

What is Autodesk Forge?

4. Data Management API

The Data Management API gives you a unified and consistent way to access your data across BIM 360 Team, Fusion Team, BIM 360 Docs, A360 Personal, and its own Object Storage Service. The Object Storage Service allows your application to download and upload raw files (such as PDF, XLS, DWG, or RVT). Coupling this API with the Model Derivative API, you can accomplish a number of workflows, including accessing a Fusion model in Fusion Team and getting an ordered structure of items, IDs, and properties for generating a bill of materials in a 3rd-party process. Or, you might want to superimpose a Fusion model and a building model to use in the Viewer.

5. Model Derivative API

The Model Derivative API lets you represent and share your designs in different formats, as well as to extract valuable metadata into various object hierarchies. 60 different file input formats are supported. With this API, you can translate your design into different formats, such as STL and OBJ, but the key one is that you can have it translate your designs into SVF for extracting data and for rendering files in the Viewer.

6. Viewer

The Viewer is a WebGL-based, JavaScript library for 3D and 2D model rendering. The Viewer communicates natively with the Model Derivative API to fetch model data, complying with its authorization and security requirements. The Viewer requires a WebGL-canvas compatible browser:

Chrome 50+

Firefox 45+

Opera 37+

Safari 9+

Microsoft Edge 20+

Internet Explorer 11

7. Webhooks API

The Webhooks API is currently undergoing beta testing internally and by Autodesk partners. A webhook sends data to endpoints (URLs) when a certain event occurs. It is triggered by events occurring in web applications. It then sends real-time data to applications listening to it. Since the data is sent immediately, using a webhook is more efficient that frequently polling for updates.

The Forge Webhooks API allows your application to listen to Forge Data Management events and receive notifications when they occur. When an event is triggered, the Forge Webhooks API sends a notification to a callback URL you have defined. You can customize the types of events and resources to receive notifications for. For example, you can set up a webhook to send notifications when files are modified or deleted in a specified hub or project.

The basic workflow is:

Identify the data you want to receive notifications for.

Use the Webhooks API to create one or more hooks.

The Webhooks API will notify the webhook when there is a change in the data.

Autodesk has always been an automation company, and today more than ever that means helping people make more things, better things, with less; more and better in terms of increasing efficiency, performance, quality, and innovation; less in terms of time, resources, and negative impacts (e.g., social, environmental). Autodesk Forge is an integral part of our automation plans.

So, regardless of the number of gigabytes of data you have in your design files, you can use these APIs to extract data, surface it, and allow your customers to view and interact with it on your own website.

Essentially, to forge is to make or shape a metal object by heating it in a fire or furnace or beating and hammering it. In the context of Autodesk’s Forge, data is the metal, and the APIs are the heat.

A Conversation With Ron Locklin, Director of Strategy and Business Development, Autodesk Forge

At Autodesk University 2017, we spoke with Ron Locklin, Director of Strategy and Business Development, Autodesk Forge about the past, present, and future of the Forge platform.

MCADCafe: What prompted Autodesk to create the Forge development platform in the first place?

Autodesk: There are actually multiple factors involved with internal and external aspects as an investment. Internally, we wanted to ensure that we built the right components, so-called Forge services, that could be used for code reuse to maximize efficiency across the company. These included a workflow engine and data management structure because we didn’t want to deal with this and other things multiple times and have incompatible things built, such as multiple data managers for different vertical industries. For internal purposes, we felt to have a development platform that was standardized and the entire company could leverage made a lot of sense. Externally, it’s good to have one set of services that are compatible, we felt we had advantages in certain market segments, and felt the development platform would benefit several of our partners and customers for them to build off of. The development platform would also broaden our market appeal – especially with our cloud offerings to small- and medium-sized businesses that our competitors can’t touch because they are largely server based.

The Forge development advantages for our partners are huge because they can build off of Forge just like we do internally, just as we did with AutoCAD and the Autodesk Developers Network (ADN) years ago. Forge lets us build out our development ecosystem dramatically using the Forge approach. However, Forge has not replaced ADN, but rather, supplements it, and ADN developers can also be Forge developers.

Initially, we were focused on Fusion and the design and manufacturing markets, but realized early the huge appeal for the Forge approach in other markets, such as AEC, and media and entertainment. We have also seen increasing interest in not small- and medium-sized businesses, but large companies, as well, because they like the standardization and efficiency that Forge provides for cloud-based software development and potentially new revenue streams that aren’t tied to server-based architectures.

Ron Locklin, Director of Strategy and Business Development, Autodesk Forge At Autodesk University 2017

MCADCafe: Can you discuss a generic/typical workflow process for developing a Forge app?

Autodesk: It’s really more about steps or pieces than a true workflow. At this point, there is no “typical” process, because the markets we serve, such as construction and media/entertainment are so different, but there are several common components. We have what we call “accelerators,” where software development customers can come for one-on-one training/enablement and leave with a working app, whether a proof of concept or more advanced stage going into production.

MCADCafe: Can you provide some broad strokes regarding the future and direction of Forge?

Autodesk: There are a lot of things coming and we have a detailed roadmap. A couple of the biggest new things are reality capture services and the Forge Application Framework that broaden the appeal of Forge. Webhooks (now in Beta) is another thing that provides for much quicker integration.

The biggest Forge market segments now are enabling software development in construction and design/manufacturing, especially advanced manufacturing where design is connected to manufacturing.

Finally, Forge is growing far beyond just accessing the APIs and you’ll see a lot of announcements throughout the year and at AU 2018, including capabilities for generative design.

Since its inception, I have thought Autodesk was really on to something good with the Forge platform/developer initiative. I also know that some of Autodesk’s competitors are keeping a close eye on it as it continues to develop and evolve. At this time, the company with the most to gain from a move such as Autodesk’s would be PTC and its continuing push into IoT. Whether this actually happens is up in the air, as Autodesk and PTC have completely different cultures, legacies, expectations, and customers. Still, PTC is pushing its “IoT technology platform,” so it might be interested in extending it as a “development platform,” as well. Where PTC will go with it is anybody’s guess. In any case, I like where Autodesk is going with its Forge platform that will continue to proliferate throughout the Autodesk ecosystem of vertical markets.

]]>https://www10.mcadcafe.com/blogs/jeffrowe/2018/08/09/autodesks-forge-transforming-the-future-of-making-things/feed/03162Xometry Continues On-Demand Roll With Acquisition And New Fundinghttps://www10.mcadcafe.com/blogs/jeffrowe/2018/07/26/xometry-continues-on-roll-with-acquisition-and-new-funding/
https://www10.mcadcafe.com/blogs/jeffrowe/2018/07/26/xometry-continues-on-roll-with-acquisition-and-new-funding/#respondFri, 27 Jul 2018 00:00:38 +0000https://www10.mcadcafe.com/blogs/jeffrowe/?p=3137A number of companies over the past several years have proclaimed that they have the answer for resurrecting manufacturing in the U.S. Unfortunately, several of these efforts have turned out to be little more than chest beating without much real substance. Then, a company came along about four years ago that really had a concept and plan for making a difference for the future of manufacturing in the U.S. – Xometry.

Xometry, the largest on-demand manufacturing platform, announced earlier this month that it has acquired MakeTime, another leading on-demand manufacturing company. This acquisition brings together the country’s two top manufacturing network platforms. The combined company will operate under the Xometry brand name and have offices in Maryland and Kentucky.

The acquisition will allow Xometry to grow its national partner network of manufacturers from 1,100 to more than 2,300 while gaining MakeTime’s enterprise product expertise and features including their Autodesk Fusion add-in and Shop Advantage program. Drura Parrish, MakeTime Founder and CEO, will join Xometry as Executive Vice President for Platform.

Foundry Group, one of MakeTime’s investors, will lead a new $25 million round of funding for the newly combined company. Almaz Capital, BMW i Ventures, GE Ventures, Highland Capital Partners and Maryland Venture Fund will also contribute to the round. Xometry has now raised a total of $63 million to date.

Xometry and MakeTime: The Future of Manufacturing

“We’re thrilled to combine Xometry’s online manufacturing platform with MakeTime’s proven success in building a distributed network of over 1,000 manufacturers,” said Randy Altschuler, co-founder and CEO of Xometry. “This acquisition will provide our customers with access to massive capacity through the industry’s largest distributed manufacturing network as well enhanced product features.”

“We’re excited at the prospect of joining forces with Xometry,” said Drura Parrish, CEO and Founder of MakeTime. “We’ve both been building the future of manufacturing, and now we will be able to offer small- and medium-sized manufacturers access to more jobs, more opportunities for growth and advanced products to power their businesses.”

Xometry has continued its rapid market expansion, recently eclipsing 10,000 customers across multiple vertical industries, including aerospace, automotive, consumer, and medical devices. In the first five months of 2018, Xometry more than doubled both its revenues and bookings versus the same period in 2017. The company also recently launched a new version of the Xometry Instant Quoting Engine, that provides virtually instant quotes on uploaded CAD files.

Foundry Group’s Seth Levine will join Xometry’s Board of Directors. “We are thrilled to help Xometry capture greater share of the $80+ billion on-demand manufacturing marketplace,” said Levine. “By combining both MakeTime’s complementary technology and partner network to Xometry’s, we can accelerate platform development and revenue growth to the benefit of both our customers and network partners.”

A Little Background On Xometry

From its inception, Xometry has been a company committed to bringing manufacturing back to the U.S. with its software platform for building a reliable and scalable manufacturing program. It employs a unique machine-learning approach that provides its customers with optimal manufacturing capabilities at the best price based on parameters input by customers.

Xometry: Revitalizing American Manufacturing

Founded in 2014, Xometry hopes to transform American manufacturing through a proprietary software platform that provides on-demand manufacturing to a diverse customer base, ranging from startups to Fortune 100 companies. The platform provides an efficient way to source high-quality custom parts, with 24/7 access to instant pricing, expected lead time and manufacturability feedback that recommends best processes and practices. With well more than 100 manufacturing partners, the manufacturing capabilities include CNC machining, 3D printing, sheet metal forming and fabrication, and urethane casting with over 200 materials. Xometry’s customers include General Electric, MIT Lincoln Laboratory, NASA, and the United States Army.

Xometry’s technology platform enables it to leverage the expertise and capacity of more than 200,000 manufacturers across the United States, most of whom have less than 20 employees. Xometry’s partners are spending less time bidding for new business and more time producing parts.

Xometry employs strict quality control protocols to ensure it’s only offering up the best vendors. When a manufacturer initially signs up to join the network, Xometry screens the company by giving it only one job to complete. Instead of shipping the product directly to the customer, it’s first sent to Xometry; where their team assesses the quality of the product and whether it meets standards established by the customer and Xometry. Customers are also encouraged to rate their vendors based on their performance, and any manufacturers flagged for producing poor-quality products will receive additional scrutiny from Xometry.

Video Interview With Xometry at SOLIDWORKS World 2017

For some time, Xometry has had an especially close relationship with DS SOLIDWORKS. Xometry’s capabilities are available as a free SOLIDWORKS Instant Quoting add-in that can be accessed directly from the SOLIDWORKS interface.

Some of the features available in the SOLIDWORKS add-in include:

Instantly price a design inside SOLIDWORKS

Feedback on how to best make the parts

Transparent and instant lead time estimation

Add notes and drawings to further specify part features, finishes, and tolerances

Insight into pricing, lead-times, and manufacturability impacts for materials and processes

Re-quote directly in SOLIDWORKS to explore design iterations

Access manufacturability resources, guidelines, and knowledge base

Is Xometry the first company to explore the possibilities of on-demand manufacturing? Well, no, not exactly. However, we have been impressed with the company’s approach, growing partner network and customer base, and the relationships with customers and partners, as well as the substantial financial connections that continue to help it down a bright path.

CTC is an independent, nonprofit, applied scientific research and development professional services organization.

“Sciaky is excited to work with CTC and help educate its clients about the real-world benefits of EBAM technology,” said Scott Phillips, President and CEO of Sciaky, Inc. “When compared to traditional forging methods, EBAM offers significant competitive advantages for customers all over the world by drastically reducing production time, waste, and costs associated with manufacturing large, high-value metal parts.”

“We are extremely pleased to announce this newly formed strategic partnership with Sciaky,” said Edward J. Sheehan, Jr., President and CEO of CTC. “We are grateful for this opportunity to collaborate with the talented team at Sciaky. Our clients will realize numerous benefits thanks to this arrangement.”

Sciaky’s Electron Beam Additive Manufacturing (EBAM) Process

Widely regarded as the most scalable metal additive manufacturing solution in the industry (in terms of work envelope), Sciaky’s EBAM systems can produce parts ranging from 8 inches (203 mm) to 19 feet (5.79 meters) in length. EBAM is also the fastest deposition process in the metal additive manufacturing market, with gross deposition rates ranging from seven to 25 lbs. (3.18 to 11.34 kg) of metal per hour. EBAM brings quality and control together with the Interlayer Real-time Imaging and Sensing System (IRISS), a real-time adaptive control system for the metal 3D printing market that can sense and digitally self-adjust metal deposition with precision and repeatability. This closed-loop control is the primary reason that Sciaky’s EBAM 3D printing process delivers consistent part geometry, mechanical properties, microstructure, and metal chemistry.

Whereas large-scale forgings and castings can take several months to complete, EBAM can produce high quality, large-scale metal structures, made of metals such as titanium, tantalum, and nickel-based alloys in days, with relatively little material waste.

In addition, the EBAM process can be used in any phase of the product life cycle: from rapid prototypes and production parts to repair and remanufacturing applications.

How Does EBAM Work?

With an .stl file from a 3D model, Sciaky’s electron beam gun deposits metal (via wire feedstock), layer by layer, until the part reaches near-net shape and is ready for finish machining. Sciaky’s IRISS (Interlayer Real-time Imaging & Sensing System) is a patented closed-loop control that provides consistent part geometry, mechanical properties, microstructure, and metal chemistry.

With an EBAM dual wirefeed system, you can combine two different metal alloys into a single melt pool, managed with independent program control, to create “custom alloy” parts or ingots. You also have the option of changing the mixture ratio of the two materials, depending upon the features of the part that you are building, to create “graded” parts or structures. You also can alternate between different wire gauges for finer deposition features (thin wire) and gross deposition features (thick wire). These unique benefits are exclusive to the EBAM dual wirefeed process and are not available with any other metal additive manufacturing.

Parts and structures up to 19 ft. x 4 ft. x 4 ft. (5.79 m x 1.22 m x 1.22 m) – or round parts up to 8 ft. (2.44 m) in diameter – can be produced with Sciaky’s EBAM machines. While large-part metal additive manufacturing is itsspecialty, EBAM can also be effective for smaller-scale parts and applications, too. In general, parts starting around 8 in.³ (203³ mm) and larger are the best candidates for the EBAM process.

EBAM Benefits

In a nutshell, Sciaky’s EBAM process has a number of advantages and benefits that include:

Reduces material costs, lead times, and machining times (as much as 80%) vs. conventional manufacturing

A cost-effective additive manufacturing process for producing large metal parts

EBAM’s dual wirefeed process can feed two different metal alloys into a single melt pool to create parts made of custom alloys. It also allows designers to vary alloy mixtures to produce graded parts. Graded parts can also be produced by switching from thin wire (fine deposition) to thick wire (gross deposition) feedstock

EBAM works exceptionally well with refractory alloys and produces significantly less material waste (a big cost-savings advantage). Wire feedstock is significantly less expensive than powder feedstock, it is easier to store, and isn’t highly flammable like some powder feedstocks

With EBAM’s pure vacuum environment, the process doesn’t require the use of argon or any inert gas for part shielding

Start 3D printing parts in as little as 12 minutes. While EBAM pump down times can vary by chamber size and application, it is still the fastest metal AM process in the market when you consider EBAM’s deposition rate

Sciaky is hardly alone in the burgeoning metal segment of the AM industry, but the sheer size, scalability, and materials of the parts they can handle is impressive. The new partnership with CTC should benefit both parties, as well as their mutual and respective customers.

Editor’s Note: All-Electric Volkswagen Wins Pikes Peak Hill Climb!

Last week we talked about Volkswagen competing in the upcoming Pikes peak Hill Climb with its innovative all-electric sports car, the Volkswagen I.D. R Pikes Peak.

Well, it prevailed and shattered the time record at the event, finishing in 7.57.148 minutes, Volkswagen Driver Romain Dumas (F) crossed the finish line in Volkswagen’s first-ever, fully-electric race car, the I.D. R Pikes Peak – a next-generation racecar developed with ANSYS simulation solutions.

“Behind the wheel of the 680-horsepower sports car prototype, Dumas mastered the track and the battery cooling system performed precisely as our simulations predicted,” said François-Xavier Demaison, technical director at Volkswagen Motorsport and I.D. R Pikes Peak project. “ANSYS provided us the competitive edge to outperform the high altitude and challenging turns and set a new world record.”

Well done, VW!

]]>https://www10.mcadcafe.com/blogs/jeffrowe/2018/06/28/sciaky-partners-with-concurrent-technologies-to-produce-big-am-parts/feed/03097VW Unveils First All-Electric Hill-Climbing Race Carhttps://www10.mcadcafe.com/blogs/jeffrowe/2018/06/21/vw-unveils-first-all-electric-hill-climbing-race-car/
https://www10.mcadcafe.com/blogs/jeffrowe/2018/06/21/vw-unveils-first-all-electric-hill-climbing-race-car/#respondFri, 22 Jun 2018 00:00:17 +0000https://www10.mcadcafe.com/blogs/jeffrowe/?p=3084Volkswagen Motorsport is charging to the start line of the Pikes Peak International Hill Climb, thanks in part to a new collaboration with ANSYS to develop its first-ever, fully-electric race car — the Volkswagen I.D. R Pikes Peak. With a goal of setting a new time record for electric cars at the race, Volkswagen Motorsport tapped into ANSYS’ Pervasive Engineering Simulation solutions to create a digital prototype of the battery system and optimize the electric propulsion system of the I.D. R Pikes Peak race car.

Behind the wheel of the 680-horsepower sports car prototype, Volkswagen Driver Romain Dumas will attempt a new time record for electric cars at the 96th edition of the Pikes Peak International Hill Climb Race.

The aerodynamic design of the I.D. R Pikes Peak car was developed for extreme conditions and to meet the specific challenges of the Pikes Peak International Hill Climb.

High altitude results in about 35 percent lower air density, which creates different aerodynamic conditions than a racetrack on flat land. In addition to real-time data and results, ANSYS solutions were used to simulate driving conditions that cannot be recreated in a traditional wind tunnel. With ANSYS solutions, Volkswagen engineers calculated the ideal balance of cooling airflow and aerodynamic loss and determined the best battery cooling strategy for optimal performance of the vehicle.

Volkswagen I.D. R Pikes Peak Test Drive

“Perfect energy management is a critical factor for beating the record in the electric car category at Pikes Peak,” said François-Xavier Demaison, technical director at Volkswagen Motorsport and I.D. R Pikes Peak project manager. “The first test drive at Pikes Peak was successful and demonstrated the accuracy of our simulations. Our team is confident in the vehicle’s performance and eager to set a new record in the category.”

“ANSYS is driving advancements in electrification and next-generation vehicles with multiphysics solutions and Pervasive Engineering Simulation,” said Shane Emswiler, Vice President and General Manager at ANSYS. “The Pikes Peak project demonstrates the importance of ANSYS simulation solutions as customers tackle new challenges and explore new frontiers in electric propulsion.”

It’s been more than 30 years since Volkswagen last entered the legendary road race, charging up the hill in a 652-hp twin engine Golf but falling short of the finish line due to suspension failure. The German automaker’s return is as much about proving its racing credentials as it is about its overall electric vehicle strategy, which will be headlined by its I.D family of zero-emission vehicles. The Crozz crossover, Kombi-inspired Buzz and the steering-wheel-free Vizzion are all concepts that have been proposed as future members of the I.D. range.

The I.D. R Pikes Peak was actually unveiled in April in Alès, France. Just like the Golf in 1987, it is powered by twin engines, but electric.

“It was absolutely fantastic to see the completed I.D. R for the first time, and to take it out for its first spin,” said Romain Dumas, who is a three-time winner of the hill climb on Pikes Peak. “What Volkswagen has managed to put together from scratch over the past few months has my greatest respect. I had obviously seen initial pictures of the car – but it is even more spectacular in the flesh.”

Driving Electromobility To The Top

“Volkswagen’s goal is to reach the pinnacle of electromobility with the I.D. family. As such, Volkswagen’s involvement on Pikes Peak not only sets the trend for our future in motorsport, but is also of great symbolic significance in the truest sense,” said Volkswagen Member of the Board of Management of the Volkswagen Passenger Cars brand with responsibility for Development, Dr. Frank Welsch. “Customers have always benefitted from the findings made in motorsport, and we expect to take these findings and use them as a valuable impetus for the development of future I.D. models. The hill climb on Pikes Peak will definitely be a real acid test for the electric drive.”

With two electric motors generating 500 kW, 650 Nm of torque and weighing less than 1,100 kg, the goal of the car is to beat the existing record of 8:57.118 minutes for electric cars at the “Race to the Clouds”. To achieve this, the I.D. R Pikes Peak will literally sprint into the future: 0 to 100 km/h in 2.25 seconds is faster than Formula 1 and Formula E cars. VW says it reclaims around 20 percent of its energy through regenerative braking.

“The car looks fantastic and has already been attracting a lot of interest from the media and on social media channels for a few weeks,” said Jürgen Stackmann, Member of the Board of Management of the Volkswagen Passenger Cars brand with responsibility for ‘Sales, Marketing and After Sales’. “This project shows once again that Volkswagen is on the right track with its major E-mobility strategy and the introduction of the I.D. family. The I.D. R Pikes Peak and the start at the most iconic hill climb in the world offers Volkswagen the magnificent opportunity to charge the topic of E-mobility, both emotionally and from a sporting perspective.”

The primary goal when developing the Volkswagen I.D. R Pikes Peak was to find the ideal balance between energy capacity and weight. The focus was not, as is usually the case with racing cars, on maximum performance. Volkswagen’s prototype for Pikes Peak justifiably bears two quality seals in its name. The “R”, which is synonymous with performance cars. And the “I.D.” – the symbol of Volkswagen’s smart E-technology.

“As with the Volkswagen brand’s production vehicles, fully-electric racing cars will also play an increasingly important role for us in the future,” said Sven Smeets, Volkswagen Motorsport Director. “The cooperation within the group really helped us, particularly given the tight schedule. For example, we received support from the Volkswagen battery plant in Braunschweig and worked together with the technical development department in Wolfsburg.”

As in production vehicles with electric drive, lithium-ion batteries are used as the energy storage system. There is great demand on the battery cells. Their power density is the crucial factor for the system when producing high voltage. Unlike in the manufacturing of production vehicles, the goal of the motorsport engineers was not maximum range, but the highest possible power output on the way to the Pikes Peak summit.

It is one of the peculiar challenges on Pikes Peak: Testing on the 19.99-kilometer route of the hill climb in Colorado Springs is only very limited, and only possible on certain sections. For this reason, the bulk of the testing was not done on the actual route, but at racetracks.

Start at 2,862 meters above sea level, 1,440 vertical meters of climbing, 156 corners, 100 per cent asphalt, and just one single attempt – not only must the technology and driver be on top form as they attempt to set a new record for electric cars, but the external conditions must also play ball. It is not unheard of for the 4,302-meter summit of Pikes Peak, which also represents the finish, to experience temperatures below freezing point at the end of June.

This is exciting because as a long-time Colorado resident, I have driven and participated in running races up Pikes Peak, and it’s no easy task (even at relatively slow speeds). I’m excited for VW and the all-electric I.D. R Pikes Peak and wish the team the best.

]]>https://www10.mcadcafe.com/blogs/jeffrowe/2018/06/21/vw-unveils-first-all-electric-hill-climbing-race-car/feed/03084Stratasys Has Tough First Half, Looks Ahead To Futurehttps://www10.mcadcafe.com/blogs/jeffrowe/2018/05/31/stratasys-has-tough-first-half-looks-ahead-to-future/
https://www10.mcadcafe.com/blogs/jeffrowe/2018/05/31/stratasys-has-tough-first-half-looks-ahead-to-future/#respondFri, 01 Jun 2018 00:00:27 +0000https://www10.mcadcafe.com/blogs/jeffrowe/?p=3040Given enough time, virtually all companies experience ups and downs, highs and lows, and peaks and valleys. It goes without saying that these cycles are inevitable in the course of any business, and an industry that seems to have more than its share of major swings is additive manufacturing/3D printing, and a company that has had its share of these cycles of late is Stratasys.

As an example, this week, Stratasys Ltd. announced that Ilan Levin decided to resign from his positions as CEO and Director, effective June 1, 2018.

Elchanan (Elan) Jaglom, the Company’s current Chairman of the Board, will serve as CEO until a successor is appointed. Mr. Jaglom’s service in the position of Chairman and CEO simultaneously requires shareholder approval in accordance with Israeli law. Stratasys plans to call a shareholder meeting to seek that approval. Mr. Levin will provide ongoing consultancy services to the Company following his resignation, as needed.

The Company’s Board of Directors has appointed an Oversight Committee to help support the management of the Company during the interim period, until a successor is appointed. The committee is comprised of the Company’s Vice Chairman of the Board, Executive Director and former CEO, David Reis, along with additional Directors Scott Crump, previous Chairman and Founder, and Dov Ofer.

The Company’s Board of Directors also established an Executive Search Committee, composed of Mr. Jaglom and Victor Leventhal, the Chairman of the Compensation Committee of the Company’s Board of Directors, to oversee the engagement of an international executive search firm to help identify a new CEO.

“The Board of Directors is appreciative of Ilan’s contributions to Stratasys and Objet for over 15 years,” said Elan Jaglom, Stratasys’ Chairman of the Board. “Ilan has implemented a number of key decisions as CEO that have kept the Company strong and ready for future expansion. We thank Ilan for his dedicated leadership of our Company during this phase in Stratasys’ history.”

Abrupt though Mr. Levin’s departure may be, it’s not totally unexpected or unprecedented based on recent and not so recent company performance.

Downward and Upward Trends

Levin’s departure ends a month that started with disappointing first quarter financial results for Stratasys.

As exciting as the 3D printing/additive manufacturing (AM) space has been the past several, especially the last couple years, its unbridled enthusiasm and expectations couldn’t be expected to go on forever, and they’re not. As a result, Stratasys reported less than anticipated financials for Q1 2018.

The figures revealed the realities of the company’s finances for the quarter and guidance for the future. These general negatives included:

Revenue was down 6% for the first quarter to $153.8 million, compared to $163.2 million for the same quarter last year.

GAAP net loss for the first quarter was $13.0 million, or ($0.24) per share, compared to a loss of $13.9 million, or ($0.26) last year.

Net R&D expenses for the quarter were $25.1 million, an increase of 1.9% compared to the same period last year.

No mention of Q1 machine sales was made.

The recent financial and executive announcements did not go unnoticed by investors as the Stratasys stock price today (13:00 Mountain time, May 30, 2018) stands at just under $19/share; down from a 52-week high of $29.00, and down from $131 just a few years ago.

“We are disappointed with our revenue for the first quarter, which is primarily attributed to underperformance in North America related to high end system orders, specifically from customers in government and other key verticals such as aerospace and automotive,” said Ilan Levin, Chief Executive Officer of Stratasys. “We do not believe that our first quarter revenue represents a fundamental change in the demand environment in the North American market. We continue to maintain a strong pipeline of opportunities, and are not modifying the full year guidance we issued earlier this year. Despite our revenue results in the period we continued our positive trend of operational discipline and cash generation. We remain committed to our investments in long-term initiatives that include advancements in our core FDM and PolyJet technologies, new metal additive manufacturing platform, advanced composite materials, and software and application development.”

Part properties achievable with the technology include final parts with density and isotropy that is significantly higher than existing additive solutions, and near identical chemical composition compared to parts created by conventional casting methods.

The solution has been optimized for production rather than prototyping, making it highly efficient and commercially viable for a wide range of applications.

For the first time, Stratasys showcased end-use production parts produced on the new metal platform.

A Brief Overview of Stratasys Events

As a company, Stratasys has been busy the past few years with the following events:

April 2012 – Stratasys Merges With Objet

With the 3D printing merger of Stratasys and Objet coming together, this was a biggie for the 3D production sector because the combined company could be valued at well over a billion dollars.

This was a good move for each of the companies because the technologies and markets for the respective companies were different. Publicly traded Stratasys was a leading manufacturer of 3D printers and production systems for prototyping and manufacturing applications, whereas privately held Objet Ltd. was a leading manufacturer of 3D printers for rapid prototyping.

At the time, the transaction positioned the combined company as the leader within the high-growth 3D printing and direct digital manufacturing industry.

August 2012 – Stratasys and HP End 3D Printer Relationship

Not all marriages are made in heaven, and the news that Stratasys and HP agreed to discontinue their manufacturing and distribution agreement for 3D printers, effective at the end of 2012 proves it. The relationship lasted only a couple of years.

Stratasys said it did not expect the termination of its agreement with HP to have a material impact on its financial results for the current year and intends to work closely with HP to ensure a smooth transition for customers. I doubt, though, if the same held true for HP.

Under the terms of the definitive agreement signed in January 2010, Stratasys developed and manufactured for HP an exclusive line of 3D printers based on Stratasys’ Fused Deposition Modeling (FDM) technology.

To be fair to HP, though, it only got Stratasys’ entry level UPrint and Dimension product lines. I think this was done to expand Stratasys market presence and installed base without cannibalizing its more lucrative high-end 3D printer market that it wanted to keep.

June 2013 – “Open Source” MakerBot Acquired By Stratasys

MakerBot, once the progeny and a proponent of the open source hardware/software movement is being acquired by Stratasys for over $400 million. Not bad for a company whose origins are the open-source community.

I used open source and MakerBot in the same sentence rather loosely because MakerBot became pretty closed and proprietary not all that long after its inception in 2009. It certainly began with an open-source design based on the RepRap Project, but effectively became a “closed” system with the advent of the Replicator 2 in September 2012. At that time, the company said it “will not share the way the physical machine is designed or our GUI.” This sudden departure from its previous open-source embrace and no longer willing to share with the community that made MakerBot possible in the first place was met with criticism in many circles. MakerBot created several products and services beyond its flagship 3D printer, which was definitely an improvement over its base design.

For its part, (and until then) Stratasys had repeatedly denied any interest in the 3D printer (under $5,000) market and would not pursue it, because their historical customer had been industrial, not the hobbyist or prosumer. Things change, though, and with this transaction, Stratasys certainly changed its tune. A customer is a customer, and with the additive manufacturing/3D printing market consolidating, Stratasys didn’t want to miss out on an acquisition opportunity that was probably being explored by competitors.

Don’t get me wrong, MakerBot’s principals made a lot of money off this deal, and there is nothing wrong with that. My issue stems from the fact that few truly benefitted from this transaction that in reality was the work of many in the open-source community. Business is business, I guess. Who says there’s no money to be made in open-source technologies?

September 2014 – Stratasys Acquires GrabCAD

Along with SpaceClaim being acquired by ANSYS earlier that year, the CAD consolidation train moved to its next stop with Stratasys announcing that it was acquiring GrabCAD.

The acquisition of GrabCAD provided Stratasys with an entirely new line of business and opportunities, and this is good for a number of reasons.

After being funded through several rounds of venture capital, the time was right for GrabCAD to be acquired by a suitor who could help it thrive into the future. Also, by being acquired by Stratasys instead of a traditional CAD vendor, continued CAD neutrality was almost certainly ensured – a really good thing.

In the end, this is one of those acquisitions that made a lot of sense on many levels and benefitted both parties, and most importantly, customers from both companies.

April 2018 – Stratasys Unveils Spin-off Focusing on New AM Technology

Stratasys officially unveiled the spin-off of its Selective Thermoplastic Electrophotographic Process (STEP) technology and forming of a new company, Evolve Additive Solutions.

After nearly 10 years as an incubation project, the new organization will be led by a dedicated management team, exclusively focused on bringing the proprietary STEP technology to market – aimed at delivering high-volume production additive manufacturing at breakthrough speeds compared to other commercially available additive processes.

The solution is intended for high-volume production runs into the hundreds of thousands per year. As such, it is expected to compete with traditional processes, such as injection molding.

Also in April 2018, the company announced enhancements to the PolyJet portfolio that include an upgraded version of the multi-material, full-color J750 3D printing platform that adds increased reliability via hardware and software enhancements, as well as the new J735 3D printer with a smaller build size.

Hopefully, these latest financial results and executive departure are only temporary setbacks, but Stratasys is hardly alone in the current 3D printing negative column.

This is not to say that Stratasys won’t make a comeback; it certainly might, but to the same level of excitement and expectations, that remains to be seen. I’m hoping (I’m sure as are many stockholders) that reality starts replacing hype, and hopes of short-term windfall profits are replaced with a more rational and patient outlook at Stratasys (and competitors) as a calculated risk investment and not a guarantee of overnight and continuous riches.

]]>https://www10.mcadcafe.com/blogs/jeffrowe/2018/05/31/stratasys-has-tough-first-half-looks-ahead-to-future/feed/03040ESPRIT CAM Software: Smart Machining From The Cloud To The Manufacturing Floorhttps://www10.mcadcafe.com/blogs/jeffrowe/2018/05/09/esprit-cam-software-smart-machining-from-the-cloud-to-the-manufacturing-floor/
https://www10.mcadcafe.com/blogs/jeffrowe/2018/05/09/esprit-cam-software-smart-machining-from-the-cloud-to-the-manufacturing-floor/#respondWed, 09 May 2018 15:00:34 +0000https://www10.mcadcafe.com/blogs/jeffrowe/?p=2947DP Technology and its ESPRIT CAM System deliver a wide range of machining solutions for Industry 4.0 smart manufacturing.

DP Technology Corp is a privately held company co-founded in 1982 by Daniel Frayssinet and Paul Ricard. The company gets its name from the first names of the co-founders – (D)an and (P)aul. The company’s corporate headquarters is in Camarillo, California. The rest of the company is structured by function with offices in France, Germany, India, Italy, China, and Japan.

DP Technology is the developer of the diverse ESPRIT CAM System sold and supported via the company’s regional offices and its network of resellers around the world. ESPRIT has also developed close partnerships with several leading milling, turning, and wire-EDM machine tool manufacturers, including Okuma, Mazak, DMG Mori, Citizen, STAR, Mitsubishi, GF AgiCharmilles, Doosan, and Tsugami, just to name a few.

ESPRIT literally gets its name from the French noun, esprit de corps, that translates to spirit of a body of persons or group spirit; sense of pride, honor, etc. shared by those in the same group or undertaking.

DP Technology continually reinforces its commitment to its technology and customers by dedicating approximately 25% of its annual revenues to ongoing product research and development. According to Don Davies, VP of Americas, DP Technology Corp., the company also has what he called “shadow R&D,” who are application engineers in the field developing post processors and simulation solutions with machine tool OEMs and dealers.

When asked about the state of the CAM market, Davies said that it is largely fragmented into distinct segments – integrated CAD/CAM vendors, such as Dassault Systemes, PTC, and Siemens PLM Software; and independent CAM vendors, such as DP Technology, Mastercam, and other VAR-based dealers. He said each has its own advantages but thought that the dedicated efforts that independent companies specializing in CAM bring the most to the table, and obviously, he felt that DP Technology had the ability to serve up the most comprehensive product/technology lineup in the competitive CAM market.

To prepare manufacturers for an increasingly digital future, and to better support Industry 4.0 and smart manufacturing initiatives, DP Technology is focusing on a range of solutions to drive automation in manufacturing. The ESPRIT CAM System enables manufacturers to streamline workflows, prevent silos from forming during the manufacturing process, increase tool life and machine utilization, and create greater access to practical knowledge for process improvement.

Program Any Machine Tool, Machine Any Part Geometry

The company says that its ESPRIT CAM System provides programming for virtually any CNC machine tool. ESPRIT’s full-spectrum functionality includes programming for multi-axis milling, turning, and wire EDM; multitasking mill-turn machines; B-axis machine tools; and swiss machines. The company also claims that its ESPRIT system is valued by CNC programmers for its extensive suite of machining cycles, comprehensive tool control, and capacity to fully support an entire shop.

ESPRIT’s CAD-to-CAM interface directly imports just about any native part model from any source, fully intact, with no need for programmers to edit or rebuild geometry. ESPRIT directly machines from any combination of geometries — solids, surfaces, wireframe, or STL. Starting with complete and accurate part geometry can eliminate nearly all the difficulty in programming complicated parts and can dramatically reduce programming time. These all add up to huge time savers, because CAM can be quite a bit different than CAD, and machine programming is often more practiced art than learned science.

Another vital part of the CAM puzzle is ESPRIT’s universal post processor that creates the G-code needed to fully exploit any machine tool. ESPRIT provides out-of-the-box operation with a complete library of pre-defined post processors. Additional factory-certified post processors are available for most leading machine tool brands, and ESPRIT’s open architecture lets you adjust any post processor to suit your personal preferences and shop floor requirements.

Davies said, “Post processors are absolutely huge because these are the machine tool drivers, analogous to printer drivers. They are vital for CAM systems to work effectively and are essential for productivity and error-free machining. They must hand shake with ESPRIT’s simulation environment. As far as NC code generation is concerned, users often expect and need code to be edited, but this is dysfunctional and, ultimately, shouldn’t have to be done. Our target is to always make sure that the NC Code coming out of ESPRIT requires zero editing. We spend a tremendous amount time and effort toward achieving that goal, and there is a lot of R&D going on in the field to write post processors.’’

Dynamic Solid Simulation and Verification

As big a deal as simulation and verification are in the CAD world, these abilities are just as important in the CAM world, as well – in some cases more important because machine tools, cutting tools and stock material are expensive items. ESPRIT’s dynamic solid verification eliminates the need for expensive dry runs on an NC machine. Machining processes have a higher probability of succeeding because you can compare accurately rendered “as designed” versus “as machined” parts. ESPRIT’s real-time simulation and comprehensive collision detection ensure that even the most complex of parts will be machined correctly the first time.

ESPRIT provides verification information of a part program simulated within a complete machining environment, including elements, such as machine tool, fixtures, clamps, stock, and workpiece. This ability to simulate and verify minimizes downtime, maximizes manufacturing efficiency, and cuts machining costs while validating comprehensive machining processes.

Cloud-Enabled CAM and Smart Manufacturing

Davies said that cloud-enabled CAM is going in many directions, but handshaking with the cloud and the data that’s out there, along with ability to deal with BIG data is absolutely essential for success.

ESPRIT can create a digital twin of machine tools for programming, optimization, and simulation. This virtual machine ensures that whatever happens on screen will also occur on the shop floor. Workpieces and cutting tools are set up virtually, resulting in exacting simulations, greater productivity and better toolpaths for higher quality parts.

With ESPRIT, a digital thread ties together each step of the workflow from CAD design to finished part, ensuring that none of the manufacturing process is siloed. ESPRIT reads part data from CAD software and creates machine-optimized G-code and setup sheets, which it then passes on to shop floor management, tool data management, and enterprise resource planning software.

To further reinforce cloud-enabled CAM, DP Technology has partnered with, MachiningCloud Inc., an independent provider of CNC cutting tool and work holding product data, and is a single source of access to the most current product data from a wide variety of suppliers, such as Kennametal and Ingersoll. Davies said that MachiningCloud is similar to iTunes for downloading 3D digital components. The MC app allows you to quickly filter the digitized tooling and holder data along with all their detailed components very quickly, streamlining the process of developing tool lists for process planning. This is compared to historically wading through multiple catalogs to find this data and the hours to days long process. This digital data can not only be used for process planning, but can be imported directly into ESPRIT for simulation purposes. Additionally, feeds and speeds data defined by the vendor can also be utilized.

As shops move to data-driven manufacturing, integration with cloud-based databases, such as MachiningCloud Inc., further facilitates access to knowledge, product data, resources and process controls for machines, cutting tools and work holding. These cloud-enabled databases suggest factory-recommended feeds and speeds for a given cut, for quickly finding the tools needed, and provide continuously updated manufacturer product data, including drawings and models of tools and cutting tool assemblies for simulation. Because information is stored in the cloud, it is always up to date, available on demand, and can be accessed anywhere.

The ability to create digital/virtual environments that mimic the real world to quickly create process plans and simulate complex machines is the reality of today’s CAM. Not surprisingly, Davies predicts VR inside of CAM systems in the not too distant future, which is an extension of cloud-enabled CAM.

ESPRIT and MachiningCloud have a close relationship promoting Smart Manufacturing/Industrie 4.0 through their adherence to Industrie 4.0 principles, including interoperability, virtualization, decentralization, connectivity, the Internet of Things (IoT), and dealing with and handling big data.

ESPRIT Helps Customer Metri-Tech Engineering Succeed

KnowlegeBase Leverages More Than Just Knowledge

ESPRIT can provide an extensive KnowledgeBase that leverages a shop’s most important strategic assets — its best machining practices developed over the years — for maximized productivity and competitiveness. ESPRIT’s KnowledgeBase provides a “push-button” approach for any programmer or operator for determining the best method to machine a given part or feature by automatically selecting the most appropriate machining cycles, cutting tools, and machining parameters. The KnowledgeBase frees CNC programmers from repetitive part programming, letting them focus on strategic process planning to further improve best practices by quickly recognizing and setting up rules for automating machining.

With ESPRIT’s KnowledgeBase, process-specific information is stored securely and is readily available to any operator or programmer. ESPRIT uses the accumulated “knowledge” of a shop’s best practices and preferred methods to automate CNC programming. The multi-user SQL database built into ESPRIT’s KnowledgeBase provides a central repository for accumulating shop-wide machining experiences.

Knowledge-based machining, the term for artificial intelligence built directly into a CAM system, makes it possible to significantly cut programming time by capturing best practices, including machining processes and cutting conditions — leaving more time to focus on strategic process improvements and reducing time spent on repetitive tasks. ESPRIT’s KnowledgeBase solution streamlines part programming by automatically selecting the optimum processes — machining cycles, tools and conditions — for part features based on proven best practices. Recording practical knowledge via KnowledgeBase is more reliable than leaving it to memory and allows for higher levels of automation through repeatable steps. Because programming is more predictable and consistent, programmers encounter fewer problems and produce higher quality parts.

The Process KnowledgeBase provides detailed tool control and extensive process automation, automatically choosing the most suitable process to machine a given feature — including machining cycles, cutting tools, speeds and feeds, and all associated machining parameters. When a process is applied, process steps are automatically adjusted to accommodate the feature geometry and other feature characteristics. Programmers can also create new processes and update details of existing processes with the Process Manager. All machining parameters are presented in a clear visual representation of each parameter’s source and condition.

ESPRIT’s Automated Feature Recognition is a KnowledgeBase component providing CNC programmers with a new level of productivity-enhancing speed and accuracy. Automated Feature Recognition subdivides a given part into features like pockets, slots, shoulders, and holes. Each feature has a set of known physical characteristics including height, thickness, draft, volume, and area. This KnowledgeBase component automatically categorizes these features into feature cases based on a shop’s standards, terminology, and each feature’s characteristics.

ESPRIT provides machine-aware CAM programming to increase tool life and reduce cycle times. The CAM system’s ProfitMilling and ProfitTurning apps represent a fundamental change in the way toolpaths are created. Most CAM software works from the shape of the part first and considers the machine last, if at all. ESPRIT machine-aware solutions first consider the machine tool – its axes positions and their limits, acceleration, and attainable and requested cutting speeds, allowing users to run machines faster, get a better surface finish on their parts and significantly increase their tool life. As a result, with machine-aware CAM, programmers make better choices regarding toolpath, without asking the machine tool or cutting tool to exceed their own abilities, especially with super alloys.

Differentiators and CAM Trends

Davies said that DP Technology is a very CAM-centric company whose primary competitive differentiator is the level of support it provides its customers. The company’s goal is to get back to customers on support calls in 30 minutes or less. Also, all support staff receive broad CAM product and process education and rotate between various roles, such as support, teaching, development, and on-site experience, to facilitate their overall education. Additionally, plans call for doubling the size of the U.S. organization in the near future.

Davies said that ESPRIT essentially functions as a CAM operating system or platform that lends itself to automating the CAD-to-NC process. ESPRIT also accommodates families of parts that provide a better way to quickly program machines because it recognizes part features defined in CAD’s product manufacturing information (PMI), thus streamlining programming and machine setups.

With regard to CAM trends, beyond the ability to handle multi-axis and multi-turret machines, as well as continuing improved ability to deal with BIG data, Davies says he sees continued CAM industry consolidation that scares end users due to their CAM investments. Since machines are such a huge investment, they need and are expected to be able to hold tolerances for 20+ years. So, in his view, a comprehensive software family from one vendor that is able to function across a wide range of machines and processes for the long term is a panacea and one that DP Technology can fulfill.

DP Technology and its ESPRIT product line seem well positioned as machine tools and processes are getting more complex, and DP Technology is helping its customers to get the most out of them. Davies summed up what the company is all about when he said, “We make NC code that just works.” Simple and well put for a company that is on the forefront of CAM technology, both today and into the future.

Editor’s Note: DP Technology’s technical conference, ESPIRIT World 2018, is right around the corner. This year’s theme is “Driving Automation In Manufacturing,” and the conference is being held in Indianapolis, IN from June 11-15. Major sponsors include DMG Mori, ANSYS SpaceClaim, GCTech Vericut, ZOLLER, and FANUC.

]]>https://www10.mcadcafe.com/blogs/jeffrowe/2018/05/09/esprit-cam-software-smart-machining-from-the-cloud-to-the-manufacturing-floor/feed/02947RAPID + TCT 2018: Metal and Post-Processinghttps://www10.mcadcafe.com/blogs/jeffrowe/2018/04/26/rapid-tct-2018-metal-and-post-processing/
https://www10.mcadcafe.com/blogs/jeffrowe/2018/04/26/rapid-tct-2018-metal-and-post-processing/#respondFri, 27 Apr 2018 00:00:59 +0000https://www10.mcadcafe.com/blogs/jeffrowe/?p=3010This past week I had the pleasure of attending RAPID + TCT 2018, a conference and exhibition that showcases 3D printing/additive manufacturing with a myriad new technologies, materials, and processes. The event, put on by the Society of Manufacturing Engineers (SME) is a highlight of the year for us, and again, we came away overwhelmed (in a very good way) by all that we witnessed.

Much like last year, if there were three words to describe the SME’s RAPID + TCT 3D Printing & Manufacturing Event they would be metal, metal, and metal — machines producing metal parts were everywhere. This year marked the 28th event and seemed more like a mini IMTS than an additive manufacturing show with exhibitors ranging from material suppliers to post processors to traditional machining companies. There were, of course, the industry heavy hitters, but there were also a lot of startup companies exhibiting for the first time that made things really interesting.

Post-processing also got a lot of exposure as companies providing these technologies had more of a presence and recognizing that this important aspect of AM needs to be an integral part of the production process, and not relegated to being an afterthought.

This year’s theme was “3D In 360°,” meaning the industry is starting to come full circle in terms of capabilities and potential, and this theme was clearly evident in the technical sessions and on the exhibit show floor. This year continued a distinct change of industry direction from one-off rapid prototyping of parts to production quantities in the hundreds and even thousands.

Formalloy Launches New Closed-Loop Metal Deposition System

Formalloy, a relative newcomer in additive manufacturing, released the new X-series laser metal deposition system starting at $200K this week at RAPID + TCT.

Featuring options including closed-loop control, variable-wavelength lasers, and Formfeed powder feeders for gradient/bi-metallic structures, the new system is poised to make wave(length)s in the metal additive market. The X-series provides improved quality, better powder efficiency, and the ability to print with the most comprehensive list of metal alloys on the market. Each machine comes standard with the Formax Metal Deposition Head and a customizable build volume with up to 5-axes of motion.

Formalloy’s X-series utilizes real-time scanning technology to monitor build quality and accuracy, and then auto-corrects errors to achieve a part that is free of defects.

The Formax head has proven high powder efficiency and has built in quick-release features for ease of maintenance and component swaps. Formalloy designs all components and systems to utilize open standards for powder supply, allowing the user to provide their own powders if desired. The X-series provides a cost-effective solution for 3D metal part production, repair and cladding to a diverse set of industries.

Formalloy’s additive manufacturing technology utilizes Laser Metal Deposition (LMD) to create metallic parts to near-net shape, increasing the design envelope while providing a more economical solution than producing the same part with conventional methods. Formalloy’s additive manufacturing systems enable reduced machining time and nearly eliminate material waste, particularly with high-value materials such as titanium and Inconel. 3D printing parts with Formalloy’s process can provide design features that can’t be achieved with conventional manufacturing methods, such as internal cooling channels and gradient material or multi-metal parts.

Formalloy’s LMD process can produce parts with dimensions from less than 1-mm to greater than 1-meter with bead widths from 250 microns and up.

I was impressed by the quality of the parts produced with this machine and the fact that it could handle multiple metals.

Additive Manufacturing Post Processing

Clean up after anything is not usually an especially enjoyable endeavor, even where subtractive or additive manufacturing processes are concerned. This is where post processing comes in.

Traditional subtractive manufacturing is hardly alone when it comes to the need for post processing – it’s often just as critical for additive manufacturing, as well, especially for ensuring higher quality production parts..

To address this issue, PostProcess Technologies has emerged as the company that solves the challenge of making 3D printed parts “customer ready” at high volume through post processing. 3D printed parts generally come off the printer with structural support material (required to print unique geometries) and an inconsistent surface. Support removal and surface finishing are the two most common post-printing steps and are mostly completed with time-intensive manual processes, which limit the volume of parts that can be produced. Traditional manual post-printing often results in damaged and/or inconsistent parts.

The company provides a comprehensive, patented solution set including hardware, software, and consumables (think of the latter as “better living through chemistry”). PostProcess has gained rapid traction with customers across the automotive, aerospace, defense, life sciences and consumer products industries, among others.

Additive Manufacturing Post Processing

The company’s founder and CTO, Daniel J. Hutchinson, started the company by addressing a growing challenge to the additive manufacturing industry, namely, automated post processing. For the most part, while the industry has focused on the first two steps of additive manufacturing – design and build – the third step, post processing was largely overlooked. Hutchinson realized that in more than 95% of cases, the printed parts have some type of support structure that needs to be removed, and currently more than 60% of these parts need finishing. To develop a solution, he studied the additive manufacturing process from end-to-end and saw the opportunity to transform labor-intensive manual post processing through new automated technologies.

PostProcess Technologies is the only provider of automated post-processing solutions for 3D printed parts with its proprietary software along with its patent-pending machines and consumables. PostProcess Technologies literally removes the bottleneck in the third step of 3D printing – post-processing.

“We continue to hear from our customers that the post-processing of parts is becoming the bottleneck in their additive operation as prototype volumes grow into the thousands per year and production volumes grow into the thousands per day. Our technology delivers unparalleled consistency, while showing a return on investment that is often less than six months,” said Jeff Mize, Chief Executive Officer, PostProcess Technologies.

“Additive manufacturing is now being implemented in every imaginable market across a wide variety of applications. We were intrigued by the complex challenge of solving the finishing requirements across all 3D printer technologies and materials,” said Hutchinson. “We are able to deliver unmatched results for our current and future customers through precision energy management, which we achieve through a combination of proprietary software, chemistry and hardware.”

The CUBE-R extends the 3D digitizing and inspection capabilities of the MetraSCAN 3D for dimensionally measuring parts ranging from 1 m to 3 m with metrology-grade volumetric accuracy on the shop floor. Unlike conventional systems, the CUBE-R provides both speed and volumetric accuracy, and also ensures a significant increase in productivity. The CUBE-R offers a realistic and comprehensive alternative to coordinate measuring machines (CMM) and other robot-mounted, structured-light 3D scanners.

Key features and benefits of the new system include:

High productivity – Performs effective inspections on several hundred parts a day (even on dark or reflective parts with complex geometry)

Multitasking – Maximizes production cycle and throughput by offering a simultaneous operation of data acquisition and analysis in a continuous and uninterrupted measurement flow

Automatic field calibration procedure – No accuracy drift over time and continuous operation

Minimum operator training – Easy-to-use and short learning curve to keep up with fast production pace

CUBE-R is an efficient comprehensive turnkey system for automated quality control applications. The CUBE-R provides manufacturing companies with the power of optical 3D measurement and industrial automation. This CMM system optimizes the production cycle and throughput resulting in better product quality.

“Quality control managers are looking for integrated solutions that enable the detection of assembly problems earlier in the manufacturing process, all while reducing waste and down time to ensure better productivity and higher product quality,” says Jérôme-Alexandre Lavoie, Product Manager at Creaform. “The CUBE-R was designed with that in mind. It is the latest addition to our R-Series automated inspection solutions, which also include technology integration for clients looking for customized dimensional measurement solutions.”

Measurement and Inspection

Along with removing the need to inspect parts in a metrology lab, Creaform’s portable 3D measurement technologies enable inspections on the shop floor, without the need for a controlled environment, because all of its solutions can withstand the harshest environments and surrounding vibrations for maximizing the efficiency of the quality control process throughout an entire production run.

When it comes to performing routine testing of process samples there are 4 basic options of measurement and inspection instrumentation, Inline, On-line, At-line and Off-line(laboratory):

In-line equipment are simple measuring devices that are placed directly into a process stream.

Off-line instruments are designed to be in an environmentally controlled location and used by technically trained personal. They offer the greatest versatility of analysis methods but require the most man hours to perform an analysis and input the results ie they have the longest results turn around time. Laboratory instruments are used when there is a large variety of test methods required and the result turn around time is not critical.

At-line measurement equipment sits in the production area and is used by an operator. This is what the CUBE-R system is.

On-line equipment are fully automated systems used to closely monitor factors that are critical to the production process. On-line equipment able to control external devices and can be operated and monitored remotely.

Although they are different, there remains some confusion between inspection and measurement. Some think that inspection is qualitative and measurement is quantitative. I can’t say I totally agree with that because there are a few different considerations to take into account.

For example, let’s consider simple optics inspection for artifacts. Suppose the parts being inspected come from a manufacturing process that is stable—unchanging, and every part is made exactly the same way. That 20 percent of the parts have artifacts might point to a problem with that manufacturing process. On the other hand, how many people inspect the parts? If there’s one inspector who follows a defined process and inspects every part in the exact same manner, one variable is removed. This means, of course, that if there are two inspectors, you need to find out whether one of them is finding more artifacts than the other. Are they finding them in equal proportions? Does one hold the parts differently (vary the inspection process)? Is one inspection station near an air vent that might be dropping dust particles on parts waiting for inspection? There are numerous variables even in this simple example. Human judgment is a major variable.

This simple inspection may not be measuring anything, but the measurement of the results of this inspection process, over time, can tell a lot about several processes. Obviously, there are several variables to take into account.

Uncertainties such as these lead manufacturers to automated measurement as the solution. An automatic measuring machine should perform consistently, no matter who’s operating it. Assuming it’s capable of measuring the part and distinguishing bad artifacts, an automatic measuring machine can be the arbiter in the inspection process.

It isn’t unusual to use a measuring machine in the inspection process. The key point is that inspection and measurement can be highly operator-dependent if the outcome depends on the skill of the person performing the task. Because one person can perform differently from another person and an individual can perform inconsistently depending on time of day or day of the week, even highly trained personnel can introduce variability into the inspection/measurement process. On the other hand, automatic measurement devices and systems that remove operator subjectivity can be the key to consistent, reliable inspection.

The question, though, is automatic inspection always accurate? In contrast to manual methods, yes, automation provides accurate measurement that is probably an order of magnitude greater.

However, that’s a question I’ll follow-up on and attempt to answer (with the help of several industry experts) in coming weeks.

In the end, Creaform’s CUBE-R provides an off-the-shelf fully integrated automated inspection solution as an alternative to CMMs for sheet metal, castings, and composites.

After nearly 10 years as an incubation project, the new organization will be led by a dedicated management team, exclusively focused on bringing the proprietary STEP technology to market – aimed at delivering high-volume production additive manufacturing at breakthrough speeds compared to other commercially available additive processes.

Traditional manufacturers have long sought to combine the benefits of additive manufacturing with the material, quality and economics of traditional production processes. Built on Stratasys’ pioneering development and 3D printing and additive manufacturing expertise, Evolve’s STEP technology is aimed at producing parts at a cost, quality and throughput comparable to traditional manufacturing processes. The solution is intended for high-volume production runs into the hundreds of thousands per year. As such, it is expected to compete with traditional processes, such as injection molding.

“As an independent company, Evolve will best be able to focus on the advancement of the technology, provide the entrepreneurial environment and management equity incentives suitable for early stage efforts and drive the customer relationships and partnerships to foster further development and initial market adoption,” said Stratasys CEO, Ilan Levin. “As an equity stakeholder, we look forward to collaborating with Evolve and supporting this initiative to help make it a success.”

Designed for automated manufacturing and factory-floor integration, STEP empowers users to utilize production-grade thermoplastics for volume production applications across multiple industries. The scalable and extensible technology combines Evolve’s own proprietary technology with the proven capability of electrophotographic imaging.

“We are excited to introduce Evolve Additive Solutions and proprietary STEP technology,” said Steve Chillscyzn, CEO of Evolve Additive Solutions and co-inventor of STEP. “We believe the STEP technology is uniquely positioned to bridge the gap in the market not yet addressed by additive or traditional manufacturing technologies,” continued Chillscyzn. “It is the first-of-its-kind technology offering an additive method for mass production. It’s designed to deliver the benefits of additive, while handling high-volume production. And we’re confident in the Evolve team’s ability to make this technology a success.”

The STEP process combines 2D imaging technology with proprietary IP developed by Evolve to precisely align incoming layers and sophisticated bonding techniques that create final parts that are fully dense with isotropic properties of injection molding.

Specifically, STEP technology introduces a range of new features, including:

Production speeds of up to 50X faster than existing additive manufacturing solutions

Cost per part and surface quality comparable to traditional manufacturing

Isotropic properties in X, Y and Z directions on par with injection molding

Industry 4.0 and automation factory floor integration

Multiple material printing capable within the same layer

Full color printing capability – including spot and process

Evolve has already commenced seeking initial purchase orders from several leading automotive, consumer goods and aerospace companies during its alpha stage. Over the next 12 months, Evolve also plans to engage new customers to evaluate beta systems for applications in volume production environments across many vertical markets. Evolve has not yet announced the date of expected general availability of its products.

STEP Technology Provides 50x Faster 3D Printing for Production

3D printing is often called a disruptive technology, and many players in the industry are focused on bringing additive manufacturing into actual manufacturing, leveraging the benefits of this young, agile technology for production. Manufacturing represents a $12 trillion global industry, and additive manufacturing is poised to bring new capabilities alongside traditional techniques to create a new standard of faster, better scale production. To date, 3D printing has been held back from a larger impact on manufacturing due to several major factors — time, cost, and final part quality key among these. Today, a new technology emerges from stealth as a Stratasys spinoff Evolve Additive solutions is ready to introduce its completely new production-scale additive manufacturing solution to the market.

Born at Stratasys, STEP was built from its beginnings as a process targeted specifically at manufacturing. Bradshaw noted that the development project began when, in 2009, Chillscyzn and Scott Crump — the inventor of Fused Deposition Modeling (FDM) technology — sat down and asked a seemingly simple question: “If we made a system for manufacturing, what would it look like?”

As the brainstorming began, they sought input from many users of additive manufacturing and those in the business of scale manufacturing. The conclusion they reached was that there simply was not an additive manufacturing technology out there capable of production volumes and quality. And so, Bradshaw continued, the team “scoured the globe for technologies suited for manufacturing.

This search, he continued, sent Chillscyzn “on a journey of developing a technology we’re referring to as the first in 20 years that’s new to additive.” He was quick to point out that this designation was not intended to take anything away from other more recent entrants introducing unique 3D printing technologies to the market, but noted that STEP is completely unlike anything else available today, not a “takeoff from existing technologies.” Evolve set about with a mission — to introduce 3D printing for manufacturing — and built their system from the ground up, not revamping or rethinking other industrial technologies.

Focusing squarely on the needs for manufacturing, not prototyping, the team determined certain frames of cost, throughput, and mechanical properties as a starting point for their system to become competitive with injection molding. The examination period extended through 2016, studying feasibility and the science of how, why, and where the concept would work.

In the beginning of 2017, conversations with the board of Stratasys turned to how to continue to progress this new technology. Ultimately the decision was made, as investment and commercialization became a focus, to spin out Evolve into its own entity, separating STEP from the public company.

Pitting its speed for comparison against other additive manufacturing technologies is a helpful way for the growing 3D printing industry to understand just how novel this technology is — but that comparison isn’t the one Evolve Additive Solutions is really making. The comparison is truly intended to be with traditional manufacturing, bringing additive manufacturing into a whole new playing field through scale.

According to Evolve, there are five primary qualities that must be considered for a technology to be thought of as a “true manufacturing technology,” factors that “bubbled to the top with each company we talked to” in doing due diligence on market conditions during the feasibility study. “If you have three of them, that’s great, but is limited on the manufacturing side.” Covering all five is key, with categories that include:

Materials

Engineering-grade thermoplastics with isotropic properties. The Achilles heel often in AM is Z-direction; because of layer lines and processes, strength in Z-direction is limited. Evolve has isotropic properties in all three directions, key as a requirement for manufacturing.

Seeing as much as 50% of the build envelope dedicated to the building of support structures generates significant waste; with STEP, about 95% of support material is reusable.

Speed

Cycle times comparable to injection molding for low-volume runs, with the ability to get a finished part with minimal post-processing. The only requirement at that end is support removal; after removing supports, the product is finished.

Quality

Part performance on par with injection molding: “We are in that category, on par.”

Not on day one, but a future development will be a full spectrum of colors, bringing in CMYK to process color, “much like you would get in catalog printing on the 2D side.”

Multiple materials in a single build, such as a high-strength material and a soft material. An example of this would be an armrest, where the bulk of the build needs to be rigid, but the outer 10-15 layers or so require a softer touch.

Versatility

This scalable system was built from the ground up for manufacturing, and “needs to integrate from a hardware and software perspective,” functioning in as hands-free a method as possible and integrating into an existing production facility.

A future concept for the system takes its cue from injection molding in having “parts drop out of the end, out of the post-processing system to remove supports, into a bin, like injection molding does.”

On the software side, integration will be versatile as the Evolve Additive Solutions team envisions functionality for “someone progressive with the Internet of Things and the cloud” as well as someone using Oracle, Siemens NX, or other familiar software. “The thought is not having them have to run a completely different set of software; they should be able to use the machine and have it monitor things like progress and material usage the way they do today.”

Cost

For people to consider for manufacturing, cost has to be comparable with injection molding. Exact figures for the system and materials were not disclosed.

Unsurprisingly, for the innovative new technology, a good deal of the detail features into what Evolve refers to as the “secret sauce.” The top half of the machine is a 2D imagine engine, developed jointly by Kodak and Heidelberg, that the company is leveraging as a starting point, featuring customization in its electronics and hardware in a scalable system. Current system specs include a 24 x 13 x 6 inch build envelope, working with ABS and soluble support materials to 600 dpi dimensional accuracy. Minimum feature size is at a 42 micron voxel size, with layer height of .001 to .003 inches and a 22 micron particle size.

A case study with Vistatek points to a notable improvement in using STEP to create a 2,000 part run of an ABS bracket, comparing results to injection molding. Stats provided from Vistatek’s experience include:

Industrial Fiber Optic Manufacturer Injection Molding Stats

Mold Cost = $2,000

Time to Mold Creation: 2-8 weeks

Cycle time = 25 seconds per part

Cost Per Part = $2.64 (Part cost includes amortization of the mold)

Est. time to 2000 parts = 2-8 weeks

Evolve Stats

768 parts per build

3 hour build

Cycle time = 14 seconds per part

Cost Per part = $1.38

Est. time to 2000 parts = 1 day

This case study was a direct apples-to-apples comparison of exactly the same traditional part and geometry. Working with more complex parts that can take advantage of the benefits of topology optimization and other aspects viable through design for additive manufacture (DfAM) could quickly enhance the positioning of STEP’s additive manufacturing capabilities as compared to injection molding.

While quite a lot has happened since the idea’s origins in 2009, it’s all about looking ahead now for Evolve. As development accelerates, the company is now looking to align with companies that have similar goals, seeking beta partners in 2019, as well as looking for investors.

Ensuring that the manufacturing following “additive” takes center stage, Evolve Additive Solutions is well positioned to introduce STEP as a new innovative technology.

Viewing not other 3D printing companies, but injection molding and traditional manufacturing, as the competition — as the opportunity — Evolve is ready to take its place side-by-side with complementary technologies to push manufacturing into its next stages for thermoplastics.

]]>https://www10.mcadcafe.com/blogs/jeffrowe/2018/04/12/stratasys-unveils-spin-off-focusing-on-new-am-technology/feed/02997ANSYS and MachineWorks Expand Use of Polygonicahttps://www10.mcadcafe.com/blogs/jeffrowe/2018/03/15/ansys-and-machineworks-expand-use-of-polygonica/
https://www10.mcadcafe.com/blogs/jeffrowe/2018/03/15/ansys-and-machineworks-expand-use-of-polygonica/#commentsFri, 16 Mar 2018 00:00:29 +0000https://www10.mcadcafe.com/blogs/jeffrowe/?p=2963Recently, ANSYS, known for its engineering simulation software, and MachineWorks known for its machining and verification software signed an agreement to expand the use of Polygonica Polygon Modeling Software toolkit throughout the ANSYS organization.

Polygonicais a polygonal solid modeling toolkit for processing polygon mesh and is the creator of MachineWorks.

Polygonica carries out a wide range of geometric operations on polygon mesh models such as automatic solid healing, fixing self-intersections and Boolean operations. Other algorithms in Polygonica allow remeshing, simplification, offsetting and point cloud manipulation.

Polygonica is built on MachineWorks’ core technology for material removal and machine simulation, and has a wide range of applications for many sectors, including additive manufacturing/3D printing, where solving complex polygon modeling problems is required when handling defective models with vast numbers of polygons.

Polygonica is used in ANSYS Discovery Live software, ANSYS’ relatively new tool that enables fast computation of CAE analysis results using the power of local GPUs. ANSYS Discovery Live shortens the feedback loop between design and analysis and lets product designers see relevant results immediately during the conceptual design process.

Interview with ANSYS at IMTS 2016

Even though we’ve been told by a number of software vendors for several years now to use engineering simulation and analysis at the earliest stages of product development, relatively few companies have heeded the advice and actually done so. In many cases, it’s still design, break, repeat in a cycle that gets very expensive quickly trying to achieve optimized design goals. Even with all the insistence and chiding from the simulation folks, I’d estimate the percentage of design work that includes simulation early in the process as somewhere between 20-25%, although that may be a bit on the high side.

With ANSYS Discovery Live, ANSYS hopes it will break and change that cycle.

ANSYS readily admits that while Discovery Live is a means of bringing simulation to the engineering masses earlier in the development process, it doesn’t pretend to do everything for everybody, and there will always be a place for engineering simulation specialists for deeper dives. Discovery Live is targeted to early design exploration and to users new to simulation. Because it is not a solution for every simulation problem, Discovery Live does not compete with other more advanced ANSYS products, such as AIM, but data from it can be exported for more further study.

With Discovery Live, ANSYS undertook a major research and development effort to build a new simulation technology based on the massive parallel nature of graphics processing units (GPUs). For example, the newest NVIDIA GPUs can deliver capabilities that approach supercomputing levels and, when combined with Discovery Live, results can now be calculated thousands of times faster than with conventional methods (think seconds instead of hours).

Interactive Physics in ANSYS Discovery Live

Discovery Live supports fluids, structural and thermal simulation applications – enabling engineers to experiment with design ideas and see instant feedback. Users can run an analysis first approach as they design – enabling them to iterate with a 3-D model and interactively explore the impact of simple and complex changes. Discovery Live’s environment provides users with instant simulation results, tightly coupled with direct geometry modeling to enable interactive design exploration and rapid product innovation.

Hopefully, Discovery Live will bring simulation upfront where it really belongs, instead of being relegated as an afterthought. Discovery Live may finally fulfill the long held hope of simulation driving design.

Other Polygonica Adopters

ANSYS Discovery Spaceclaim software was an early adopter of the Polygonica technology, which was initially used within additive manufacturing workflows. The SpaceClaim team helped progress the Polygonica functionality to support more generic polygon-based CAD functionality.

“We are very excited that ANSYS have seen the potential for using Polygonica across their product rangeand we fully expect they will be driving us to deliver solutions to even more challenging polygon-based geometry problems,” said Dr Fenqiang Lin, Managing Director of MachineWorks.

“The agreement with MachineWorks enables ANSYS to provide the industry-leading faceted modelling capabilities of Polygonica more broadly to our customers,” said Justin Hendrickson, director, product management at ANSYS. “Our recent release of ANSYS Discovery Live brings simulation to every engineer through remarkable ease of use and dramatic speed—Polygonica extends the included geometry editing to faceted data beyond traditional CAD.”

MachineWorks Hybrid Manufacturing Simulation Software

MachineWorks is a software development toolkit used by manufacturers looking to simulate any type of CNC machining and check for clashes and gouges in the full machining environment.

According to the company, more than 60% of CAM developers in the world have integrated MachineWorks software for CNC simulation and verification. MachineWorks is integrated not only into CAM applications but into stand-alone verification applications and controller-based applications, including collision avoidance systems.

MachineWorks v8.0 providesa much simpler integration experienceby simplifying the work required to embed MachineWorks and by reducing the number of libraries needed for specific functions.

Switching between CAD and polygonal data can be frustrating and time consuming so MachineWorks has also added new modelling functionality that provides surface and feature detection capabilities.

Interview with MachineWorks at IMTS 2016

MachineWorks now provides simulation for sheet metal bending, including highly optimized collision checking and customised performance for this type of manufacturing.

The new cloud simulation functionality supports rendering of simulation in real-time even on slow network connections between client & server due to MachineWorks’ improved implementation, compression and communication tools.

A3D recording of a simulation can be performed for creating movie files within MachineWorks v8.0. The recording contains information to provide customization options on the production of a movie. This new function creates new possibilities not just for marketing but for actual manufacturing as recordings can show abnormalities otherwise undetected.

So, in a nutshell, there is a lot going on symbiotically with ANSYS, Polygonica, and MachineWorks that will benefit customers.